Saito FA-56, FA-65, FA-72, FA-80, FA-82a Instruction Manual
...
Version 2005
VERY
IMPORTANT
Failure to read
and follow these
instructions beforle
you proceed to
start your engine
may result in
engine damage
and the voiding of
your warranty.
SAFETY
INSTRUCTIONS
1
Introduction
Congratulations on purchasing a Saito
4
-
cycle engine. When cared for
properly, these high
-
quality, finely
crafted engines offer many years of
modeling enjoyment.
This instruction manual has been
developed to ensure optimum
performance from the Saito engine you
have purchased. The instructions must
be read through completely and
understood thoroughly prior to
mounting and running the engine.
Safety lnstruct
ions
This model engine will give you
considerable pleasure, satisfaction, and
performance if you strictly follow
these safety instructions and take heed
of the warnings as
to
its safe and
proper use. Remember at all times
it
is
not
a
toy,
but a precision-built
machine with more than enough power
to cause harm if misused or if the
safety precautions are not observed.
You
should
always:
1.
Mount the engine securely in a
“bench mount” or high-quality motor
mount. Never clamp the engine in
a vice.
2.
When running the engine, be sure
all spectators, especially children, are
at least
20
feet away.
3.
Use the correct size and pitch
of propeller for your engine; refer
to the “Propeller Chart”
on
page
16
of
this manual.
4.
It is extremely important to balance
the propeller prior to installation of the
engine. Failure
to
do
so
may cause
damage to the Saito engine and/or the
airframe. Install the propeller with the
convex (curved) side facing forward.
Securely tighten the propeller nut
against the washer and propeller.
An
anti-looaening nut (or “jam” nut) is
suggested for all 4-cycle engines.
5.
Inspect the tightness of the propeller
nut prior to each flight.
6.
Keep your face and body away
from the path of the propeller blades
when starting or running your engine.
7.
Never allow your hands
to
come
close
to
the propeller. Utilize either
a “chicken stick” or electric starter
to
start the engine.
8.
Discard any propeller that is nicked,
scratched, cracked
or
damaged in any
way.
9.
Make all carburetor adjustments
from behind the propeller.
10.
To
stop
the engine, cut off the fuel
supply (pinch or disconnect the fuel
line
to
the carburetor) or use the
throttle linkage to shut off the air.
2
SAFETY
INSTRUCTIONS
Do
not
use hands,
fingers,
or
any
other
part
of
the
body
to stop the propeller:
Do
not throw
any
object into
a
propeller to stop it.
It
is
highly
recommended
that:
Safety glasses or goggles be
used when starting and running
your engine.
You do not run the engine in the
vicinity of loose gravel or sand.
The propeller may throw such
materials into your face and eyes.
The engine may also ingest these
harmful materials.
Loose clothing should be avoided
when operating your model engine.
Loose clothing may become
entangled in the propeller, creating
the possibility
of
bodily harm. Also,
all loose objects (screwdrivers,
pencils,
nickle
cadmium starters, etc.)
should be removed from your
pockets
so
that they do not fall
into the propeller.
away from the propeller.
well away from sparks, heat, or
anything that can ignite the fuel.
Glow plug clips and cords are kept
Your glow fuel is kept in a safe place
Be
ware:
Model engines get very hot while
running.
Do
not attempt to handle
them until they have cooled.
Always run your model engines in a
well-ventilated area. Similar
to
automotive engines, model engines
produce possible harmful carbon
monoxide fumes.
Remember that model engines
produce a substantial amount of
power, more than enough to seriously
injure people and/or
do
considerable
damage to property. Always use
common sense, skill and constant
observation of safety precautions.
Disassembly
Do
not
needlessly disassemble your
Saito engine. Only qualified
individuals should perform engine
repairs. Damage due to improper
disassembly will not be covered under
warranty. If it becomes necessary to
repair the engine, such as after a crash,
you can send your engine to the
authorized service center at:
Horizon Hobby, Inc.
Attention: Saito Service
4
105
Fieldstone Road
Champaign,
IL
6
1822
Phone:
(217)
355-951
1
SUPPORT EQUIPMENT
3
Engine Parts
ldent
if
ication
It is important to be able to identify the
parts of your Saito engines. Attached
you will find an exploded view of a
Saito 4
-
stroke engine, as well as charts
that include part numbers and
descriptions. This will assist you in
easily and rapidly identifying the
respective parts of your Saito engine.
Support
Equipment
The following item, which
are
not included
with your Saito engine,
are
necessary
in
order to
operate
the model engine:
1.
Fuel.
For maximum protection and
longevity of Saito engines, Saito
recommends a fuel containing 20% oil
and 10
-
15%
nitro
methane. If
this
blend is
not readily available, the next best
selection is a high quality 2
-
cycle glow
fuel, such
as
Hangar 9 Aero-Blend,
Omega, Cool Power,
K&B, Power
Master, etc. Use
of
fuels composed
entirely of castor oil is
not
recommended.
A mix of synthetic
-
castor oil is acceptable
and can be found in the various fuels
described above.
2.
Propeller.
Refer to the "Propeller
Selection" chart, located on page 16, to
determine the best initial propeller for
your particular application. Propellers
should be balanced prior to use.
3.
Glow Plug Battery.
Your glow
plug may be properly heated by
several different sources. The Hangar
9
Power Panel (HAN106), when
accompanied by a 12-volt Sealed Lead
Acid Battery
(HAN102) and a Glow
Plug Locking Socket
(HAN120) is an
ideal source of heat for your glow
plug. A conventional 1.5
-
volt heavy
-
duty dry cell battery with a Glow Plug
Locking Socket (HAN120) or alligator
clips may also be used. Additionally,
there are several very good
glow-
starters (nickel cadmium-powered
glow plug igniters) that work well.
4.
Glow Plug Wrench.
Used to
remove and tighten glow plugs. The
Hangar
9
Long Reach Plug Wrench
(HAN2510) is an excellent wrench to
utilize, as a longer shaft may be necessaq
to access the glow plug.
This
depends
mostly upon engine installation.
5.
Manual
or
Electric Starter.
For
manual starts, a "chicken stick" is
highly recommended.
Never
use
your fingers to start any model engine.
To
do
so
invites injury. There are a
variety of electric starters on the
market. The Hangar
9
12V heavy-duty
Super Starter
(HAN110)
will work
perfectly on all Saito engines.
6.
Tachometer.
The use of a
tachometer for setting the high-speed
needle valve prior
to
flight is
encouraged. It will also be helpful
when setting the idle adjustment of the
carburetor(s).
4
STARTING THE ENGINE
Break
-
In
The first run
on
any engine, whether
2
-
cycle
or
4-cycle, is critical
to
the
future of the engine itself. During this
time, metal mating parts (piston and
cylinder, ball bearings, etc.) wear in.
Care must be taken that the engine is
clean and free of any dust
or
grit that
may have accumulated while building
the model.
There are two accepted methods for
breaking
in
a new engine: test stand
mounted and run or aircraft mounted
and run. Either method
is
acceptable;
however, mounting the engine
to
a test
stand allows the engine
to
be observed
throughout its operation, as well
as
elevating
it
above the ground and away
from harmful dust and dirt.
Note:
Because your engine may have
been sitting for
an
extended period of
time prior to running
it,
a few drops
of
light
oil
applied through the crankcase
breather nipple (19 on the exploded
view) and down the push-rod tubes
(40) will ensure proper lubrication
for
the first
run.
Regardless
of
the mounting method
chosen for break-in,
the
following
procedures are applicable:
1.
Use of a fuel as described in
the
“Support Equipment” section
on
page 3 of
this manual for “break-in”
purposes
is
perfectly acceptable.
2.
Use the proper glow plugs. Your
engine includes the Saito
SS
SAIP
400S
or
(HAN3011)
super glow plugs,
which are standard replacement glow
plugs for these engines.
3.
To select the correct propeller, refer
to
the “Propeller Selection” chart on
page
16
of
this manual. Remember to
balance the propeller prior
to
use
4a.
For all
.30
to
.91
engines, ensure
that the high speed needle valve
(85)
is
opened (turned counter
-
clockwise) two
and
112
turns out. This guarantees a
very rich setting.
4b.
For
all
1
.OO
to
1
.80
engines, ensure
that the high speed needle valve
(85)
is
opened (turned counter-clockwise)
5
turns out. This guarantees a very rich
setting.
Do
not
adiust the
low-speed
needle
valve (89)at this time.
The
low-speed
needle valve
is
preadjusted
at the
factory for initial break-in. Specific
instructions for adjusting the idle
of
engines (FA-30S(H)) using an
“air-bleed’ type carburetor will be
described in the section “Carburetor
Adjustments
for Air
Bleed
Carburetors”
on
page
7.
5.
The use of a tachometer is highly
recommended since the adjustment
of
a 4-cycle engine, while similar
to
that
of a 2-cycle engine, is more difficult to
“set by ear,” making
it
much easier to
damage the engine by “over-leaning.”
STARTING THE ENGINE
5
Starting
The
Engine
1.
Make sure the glow
plug(s)
is/are
installed and tightened.
2.
Be sure the propeller is properly
secured. The use of an anti
-
loosening
nut, or “jam nut,” is encouraged
on
4-cycle engines.
3.
Make sure that the fuel tank line(s)
are properly connected. The fuel
pickup line should be connected to the
carburetor spray bar
(84), and the vent
line should be connected
to
the
pressure nipple
on
the muffler. The
proper “plumbing” of the lines is
extremely important to the
performance
of
any engine. Saito
recommends the center of the tank
be mounted approximately
5
mm
lower than the carburetor center.
4.
Be certain that the muffler
is
installed properly by oiling the threads
prior
to
inserting the muffler into the
cylinder head and that the pressure line
is properly connected.
5.
Fill the fuel tank
6.
Prime the engine:
Check to make sure the glow plug is
not
connected
to
the heat source
(glow plug
clip/locking
socket)
Open the throttle fully
Rotate the propeller in a counter
-
clockwise direction 5 to 6 times
while plugging the end
of
the muffler
with your finger to draw fuel into
the carburetor.
Note:
Saito single cylinder engines
are now manufactured without the
choke valve
(92).
Due
to
the excellent
fuel draw characteristics
of
the Saito
engines, the use of the choke was
determined not
to
be necessary.
7.
Start the engine:
Turn through the prop 2 to 3 times
slowly to ensure that the engine is
not hydro-locked (see note below).
Note:
When using an electric starter,
care should be taken to be sure the
engine does not become
“hydro-
locked” (flooded with fuel). While the
electric starter will turn the engine
over, it may damage the connecting
rod or other components. If the engine
becomes hydro
-
locked, simply remove
the
glow plug and turn the engine over
a few times with the “chicken stick” or
electric starter. The excess fuel will be
forced to exit the engine via the
cylinder head.
Close throttle
to
‘/I
-
I/?
Rotate propeller clockwise
until
it
is
open position.
against the compression stroke.
6
STARTING
THE
ENGINE
Connect the heating source to the
Using either the "chicken stick'' or
glow plug.
electric starter, spin the propeller until
the engine
is
running.
Note:
A
very common error is to
remove the glow plug igniter too early.
It is suggested that the igniter be left
attached until after the engine has been
run up and the high
-
speed needle valve
has been properly adjusted.
8.
Initial break-in:
Do
not
exceed
4,000
rpm for the first
10
minutes of operation; This allows
all
parts to mate properly with good
lubrication.
Note:
Due to the excessively "rich
"
mixture setting, it may be necessary to
leave the heat source attached
to
the
glow plug.
Subsequent runs may be made while
slightly leaning out the mixture with
each tank full of fuel. Forty minutes is
considered sufficient time for normal
break
-
in prior to the first flight.
9.
After break-in:
If a test stand was used for the break-in
procedure, the engine may now be
mounted in the aircraft using a
high-
quality motor mount such
as
those
available from Saito specifically or for
Saito engines.
The idle needle valve
(89)
(or air bleed
needle valve) for the Saito
.30S(H)/
GK
engines) may now be refined.
Please refer to the
"
Carburetor
Adjustments" section on page 6 for
information on how to do
so.
The valves may
also
be checked at this
time. Refer to the
"
Engine
Maintenance" section on page 8 for
information on the valve/tappet
adjustments.
The use of
a
tachometer is encouraged
for setting the high
-
speed needle valve
(85)
prior to flight. The peak rpm
should be obtained and then reduced
by approximately
200 - 300
rpm by
turning the high-speed needle valve
counter
-
clockwise (richen). Each
engine'a peak rpm can be found on the
"
Propeller Chart" on page
16.
Over-
revving of a 4-stroke engine can cause
internal damage to the engine.
Carburetor
Adjustments
for
Two
Needle Carburetors
The low-speed, or idle needle valve
(89),
is preadjusted at the factory for
best performance during break
-
in.
After break-in it may be necessary to
"
fine tune" the low speed adjustment
using the following procedure:
1.
Start the engine and let it
warm
up
prior to attempting any adjustments.
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